Interlocking wall system



7, 1962 w. R. CALLAHAN ETAL 3,048,244

INTERLOCKING WALL SYSTEM 2 Sheets-Sheet 1 Filed April 10, 1957 FIG.- I

/' INVENTOR.

WILLIAM R. CALLAHAN B 3H LES M. Rgf-Tgti Aug. 7, 1962 w. R. CALLAHANETAL INTERLOCKING WALL SYSTEM 2 Sheets-Sheet 2 Filed April 10, 1957 FIG:H

INVENTOR. WILLIAM R. CALLAHAN ilnited htates This invention relates toprefabricated walls and component units or panels adapted for end-to-endconnection to form such walls. It relates particularly to building unitsof composite construction wherein high-strength surface elements of thinsheet material which need not be thermally nonconductive are combinedwith thermal insulating materials. The term wall, as used herein,denotes generically the various space-dividing portions of a buildingwhether it be a lateral wall, ceiling, floor or partition.

A primary object of the present invention is to provide a wall panelhaving an end edge of novel construction which renders it possible toconnect it to and disconnect it from anadjacent panel and which providesa joint with the adjacent panel which is highly resistant to the leakageof heat and fluids therethrough.

Another object is to provide extremely light weight wall units inaccordance with the foregoing object in which thin gauge metal or otherrigid material is utilized in the manner of a box girder to obtain highstrength with respect to laterally applied forces.

It is also an object to provide high thermal resistant wall-buildingunits while utilizing, if necessary, a relatively high heat-conductivematerial as the strength-supplying skin or web portions of the units.

Ancillary to the foregoing object is the construction of units in such amanner that interlocking joints of one unit with the other are formedwith a relatively heat-conduc tive skin material discontinuous withinsuch joints wherein the gaps in such material contain another materialwhich is highly resistant to heat transmission. Other objects, featuresand advantages will be apparent from the following description of theinvention and the drawing relating thereto in which:

FIG. 1 is a fragmentary vertically shortened elevation of a wallillustrating several wall units joined together;

FIG. 2 is a fragmentary top view of the wall shown in FIG. 1;

FIG. 3 is an enlarged fragmentary perspective view of the juncture oftwo units, such as illustrated in FIGS. 1 and 2;

FIG. 4 is a fragmentary perspective view with portions broken awayillustrating one arrangement for securing wall-forming units to a framemember;

IGS. 5 and 6 are plan views of units adapted for forming curved orcorner wall sections;

FIG. 7 is a plan View of a straight-sided unit adapted for connectionwith units of FIGS. 5 and 6;

FIG. 8 is a fragmentary perspective view illustrating a riveted joint ofa unit;

FIG. 9 is a fragmentary plan view of two units positioned for movinginto an interlocking position; and

FIGS. 10 and 11 are fragmentary plan views illustrating steps in joiningunits of a modified form.

Briefly stated, the invention resides in a wall-forming panel, in thecombination of a pair thereof as a hollow unit which may serve as acontainer for an insulating material, and in the assembly of a pluralityof such units as a wall. The basic structural element, the panel,comprises a self-sustaining web of sheet material having an inner faceor back side, and an outer face or front side adapted to form a wallsurface of one room, opposite side edges, and opposite first and secondend-edge-portions terminating in corresponding first and second endatent ice and narrow marginal flange which extends longitudinally edges.The first end-edge-portion forms a relatively long or lengthwise in adirection proceeding from one side edge of the panel toward the other,and transversely or widthwise in a lateral direction proceeding awayfrom the panel proper. The second or opposite end-edg'e-portion of theweb forms an elongate marginal U-shaped channel which extendslongitudinally or lengthwise in a direction proceeding from one sideedge of the panel toward the other, said channel opening away from thepanel proper in a second lateral direction proceeding opposite to thedirection in which the flange extends. In a preferred embodiment, theweb may extend generally within a major plane, the marginal flange mayextend with its major plane parallel to the major plane of the web, andthe marginal channel may extend with its outer and inner legs in spacedparallel relationship with each other but on opposite sides of the majorplane of the flange.

Such pane-ls may be joined in back-to-back relationship with the flangeof each panel extending adjacent an outer marginal portion of the outerchannel leg of the other panel to provide a tongue at each end of theunit.

In preferred embodiments, insulating materials are in corporated intothe tongues and within the body of the unit. A plurality of such panelsmay be joined in series interlocking relationship to form a wall byreason of a channel and tongue at each end of each unit adapted formating relation of the tongue and channel, respectively, of the nextadjacent unit. In a more specific form of the invention, the abuttingend surfaces of two adjacent units and an element projecting from asupport member cooperate to provide a wall comprising a plurality ofsuch units and the member.

With reference to FIGS. 1 and 2, panels or units 8 and corner units 9and 10 are secured to bottom frame member 12 and top frame members 11and 13 by hooks 14. The frame members 11-13 preferably form a rigid partof the building frame work. The hooks 14 normally will be secured tothese frame members at the time the partitions are being installed andin a manner proceeding progressively with the installation of eachpanel.

The hooks 14 project into the joints of the unit as shown in FIG. 4.They preferably are secured to the frame by welding. When this mode ofsupporting the units 8 is employed, each hook 14 may be joined to theframe member as shown by its marginal edge 14c with such edge bent outof the plane of the flat portion 14:: of the hook. As the flat portionextends perpendicularly with respect to the member, an acute dihedralangle is formed between the bent edge of the hook and the face of themember 11 which provides a, trough-like recess in which a weld 15 isformed to anchor the hook to the member.

The resulting joint is substantially symmetrical with respect to thegeneral plane of the flat hook portion 14a. Consequently, it isnecessary to provide the unit with rounded corners 8x and 8y so thatthere Will be no binding of the units with either side of the weld jointas they are placed in operative position. A further factor makingdesirable corners of radius adequate to provide clearance with the jointis the usual presence of splatter or beads of metal which stick to theparent metal adjacent a weld joint. As shown in FIG. 7, the corners Snand 8m of the units in the outer face of the wall may be formed withsmaller radii. The hooks are accommodated within the joints of thepanels in a particular manner hereinafter described.

FIG. 7 is an enlarged view of one of the units 8 as viewed in FIG. 2showing that the unit comprises two webs 16 and 17 which form thelateral sides of the unit and are turned in therefrom to form its endsurfaces and then turned out in the longitudinal direction of the unitto form flanges 19 and 2d at one end, and the flanges 21 aoaaseainterposed a strip 23 or 23a of thermally nonconductive material such ascork, fabric or paper. Extending around the outer surfaces of theflanges is a covering or channel 24 of resilient sheet material, such asa strip of rubber or vinyl plastic. Together, the flanges 21 and 22, thecork strip 23, and the outer covering strip 24 constitute a tongue 25.In a like manner, a tongue 25a is formed comprising the flanges 19 and20, strip 23a and the cover 24a. Al though the flanges of a tongue maybe otherwise secured, the channel 24 or 24a may constitute the primarymeans for holding respective tongues together by either (or both) theirrigidity, or by being adhesively joined to the flange surfaces.

Each end portion is formed with a channel adjacent its respectivetongue. For example, a channel 2% is formed in the web 16 adjacent itsflange 19. The bight of this channel is of suflicient width and the legsof the channel are of sufficient length for the channel to receive thetongue 25 of another unit 8. Likewise, a channel '27 is formed in theleft end of the panel 8 as viewed in FIG. 7 to receive the tongue 25a ofanother unit. The tongues 25 and 25a are in staggered relation withrespect to the flat face surfaces of the unit as provided by the web 16,or any other longitudinal plane of the unit. In a similar manner, thechannels 26 and 27 are in staggered relation whereby they may receivethe tongues of respective opposite ends of other similar panels or unitsand thus dispose corresponding lateral surfaces of the units in the samegeneral plane or wall contour.

In a typical unit for forming a flat wall-portion, the major plane ofthe tongue at one end of the unit extends approximately parallel to themajor plane of the unit and approximately through the middle of thebight of the channel at the other end of the unit. However, it is withinthe scope of the invention to construct a unit With the major planes ofits channels and tongues canted at a predetermined angle with respect tothe major plane of the unit.

Although the length of the tongues relative to the depth of the channelsis not a critical feature, the length of the tongues should beapproximately the same as the depth of the channels for tightest wallconstruction. When hooks projecting from supporting frame members, suchas the hook 14 of FIG. 4, are used to secure the panels to the framemember, the tongues may be slightly longer than the depth of thechannels so as to provide a slight gap between end surfaces of adjacentends of connected panels through which a hook may extend.

FIG. 8 illustrates one manner in which the flanges at the opposite endsof each panel may be secured together. As depicted, rivets 29 extendthrough both flanges 19 and 2t and the interposed cork strip 23a. Whenthe webs 16 and 17 of the unit comprise a highly heat-conductivematerial, such as aluminum or other metal, the flanges may be joinedadhesively such as by applying a thermosetting glue to the surfacesthereof in contact with the cork strip 23, and/or to the cork strip,whereupon the glue may be set by heating the tongue after assembling theunit. In this manner, all metal connection between the two webs of apanel in eliminated thereby minimizing the passage of heat therebetween.

One important advantage derived from construction of the units 8, i.e.,the construction wherein both webs terminate as flanges in a tongue andone of the webs con tains a channel which functions also to hold thetongue together which it receives, is that the strength of a Wallcomprising such units is substantially independent of the strength ofthe joint holding the two flanges at one end of the unit together. Thus,the tongue of any unit, when inserted into the channel of another unit,is permanently held together by the channel as long as the wall isassembled.

As shown in FIG. 7, the web 17 is formed with a shallow U-shaped sectionforming a lateral depression within one side of the units. Such adepression provides inwardly extending surfaces 31 and 32 which add tothe rigidity of the unit as a whole. If desired, the web 16 may beformed with a similar U-Shaped section, however, it is preferable toprovide suflicient space within the unit 8 for an insulating material.The presence of turned-in surfaces 31 and 32 in some applications willbe preferred because of the decorative effect imparted thereby to theunits. As very thin gauge metal sheets are used in forming the webs 16and 17, decorative designs are readily rolled, embossed or otherwiseformed by deformation of the body or surface of the metal sheet,

As shown in FIG. 7, the unit 8 contains a layer of insulating material33 which does not completely fill the space between the web 16 to theweb 17 with respect to the transverse direction of the unit. To make theunit completely fireproof, the layer 33 comprises a material such asglass fibers or other mineral fibers mixed with an inorganic cement torender the layer self-sustaining within the unit. For some uses of suchpanels, it is desirable to provide an air space, such as region 34,between the insulating material and one web of the unit.

With further regard to securing the units to the frame members, FIG. 4illustrates that in order to provide sufficient space within a jointbetween two units for insertion of a hook 14 a portion of the plasticcover 24 as shown in FIG. 3 may be removed. Thus, in an installationwherein such hooks are used, the upper and lower end portions of thecovers 24- for the tongues nearest the wall will be removed toaccommodate hooks M Which must go into both ends of the joints. Asstated hereinbefore, the cover (see cover 24) maybe adhered to the outersurfaces of the flanges with a glue or cement whereby the unit may beheld together permanently, or at least with suflicient strength in thetongues to hold the unit together through handling and storage untilincorporated into a wall.

FiGS. 5 and 6 illustrate non-rectilinear or non-planate units whichdiffer in direction and degree of curvature. These sections areexemplary of units that may be formed and adapted to evolve any desiredlineal direction of wal contour. The unit 2% of FIG. 5 is typical of aunit required for forming an inside right angle wall portion. Unit 30 ofFIG. 6 is arcuate with its direction of curvature opposite to that ofunit 29 and less than a right angle. The latter unit is adapted forforming rounded walls.

With a view to providing the units in a condition providing easyassembly, different modes of attachment of the cover strips or channelelements of the tongues are illustrated. FIG. 3 illustrates anarrangement wherein channel elements 35 and 36 are normally held withinthe channels 26 and 27 in the manner of window glass channels ofautomobile doors. The elements 35 and 36 may be secured, e.g., as theresult of a press fit, or adhesively. The edges of the channel elementsare rounded at 33, 39, 4t) and 41 to facilitate entry thereinto of thetongues 43 and 44. The above arrangement allows the use of covers whichextend substantially full depth of the panel channel which iscontradistinct from the arrangement shown in FIGS. 10 and 11 wherein thecovers 46 and 47, secured to the flanges, are a part of respectivetongues. The" covers are not more than half the length of the channelsor tongues in order that the tongues may be aligned for entry intorespective channels as shown in FIG. 10. The covers 24 and 24a of FIG. 7and 9 are attached as parts of respective tongues. One leg of each coverextends the full length of the tongue to which it is attached andcontinuously into the adjacent channel to substantially its full depth.Some suitable materials from which the covers or channel elements may bemade are plastic-ized vinyl resins, moderately hard vulcanizates ofsynthetic and natural rubbers, polyethylene, leather, woven fabrics withor without impregnation by a resin, and resin-impregnated non-wovenfabrics.

From the foregoing description, the invention may be observed to havesuch obvious and inherent advantages as (1) almost completeiueproofness; (2) interlocking joints which connect the unitscharacterized by (a) complete blocking of the passage of vapor, (b) ahigh degree of rigidity or box-frame elfect within the joint itself asprovided by the interlocked channels and tongues, and

() thermal non-conductivity resulting from the use of heatnon-conducting laminate for separating various metal portions within thetongues and channels of the units; (3) ease of assembling units andattaching them to supporting members; (4) high strength of the unit or awall of such units resulting from the box-frame design of the unit as awhole; (5) and the use of light-gauge web materials which are readilyworked to provide decorative surface effects.

While preferred embodiments of the invention have been shown anddescribed, it is understood that changes and variations may be madewithout departing from the spirit and scope of the invention as definedin the appended claims.

Having described our invention, we claim:

1. A prefabricated box-like wall forming unit capable of beinginterfitted with like units in edge abutting relationship to form amultiple unit, continuous wall comprising: a pair of cooperating unitforming panels, each of which is composed of a continuous sheet ofmaterial of substantially uniform thickness formed to provide aselfsustaining Web having an inner face, an outer face adapted to forman exposed wall surface, opposite side edges and opposite first andsecond end-edge-portions terminating in first and second end edges; saidfirst end-t edge-portion being bent to form a relatively long and narrowfirst marginal flange which extends longitudinally in a directionproceeding from one side edge of said Web toward the other side edge andtransversely in one lateral direction proceeding away from said facesand is offset inwardly from said inner face; the second end-edge-portionof said web being bent to form an elongate U-shaped channel whichextends longitudinally in a direction proceeding from one side edge ofsaid web toward the other side edge and opens in a second lateraldirection proceeding away from said faces; said channel including aninner leg, a bight and an outer leg with said inner leg connected withthe face portion of the web by an inward extension and extending fromthe inner edge of said extension along the inner face in a directionsubstantially opposite to said second lateral direction and proceedingto one edge of the channel bight, and said outer leg projecting from theopposite edge of said bight in a direction substantially the same assaid second lateral direction and proceeding to said second end edge ofsaid web, said inner and outer legs offset from the inner face distancesrespectively less than and greater than the offset of said firstmarginal flange, the distance between said legs being greater than twicethe combined thicknesses of said outer leg and first marginal flange andthe len th of said outer leg in said second lateral direction greaterthan the corresponding dimension of said inner leg whereby said secondend edge of said web is spaced beyond said extension in said secondlateral direction; said panels being arranged with their inner faces inspaced face-to-face relationship with each other and with the firstmarginal flange of one panel extending adjacent the outer portion of theouter channel leg of the other panel on the outside of the channel; heatinsulating means connected with and forming a part of the unit anddisposed between said adjacent flanges and outer portions of said outerlegs and also on the exterior of said flanges and outer legs andoperable to provide an insulating seal between said flange and outer legand between the flange and outer leg and the adjacent surfaces of achannel of a like wall forming unit when the flange and outer leg areinterfitted therein; and means securing the.

first marginal flange of each web to the outer channel leg of the otherweb.

2. A wall comprising: a pair of the units of claim 1 arranged inend-to-end relationship with the adjoining flange and outer portion ofthe outer leg and heat insulating means on the adjacent end of each unitextending into the adjacent channel of the other unit.

3. The wall assembly of claim 2 comprising a support member for theunits having a surface extending in the end-to-end direction of theunits adjacent to correspondingly similar faces of the units, the memberhaving means projecting laterally with respect to said surface and extending between the end surfaces of an adjacent pair of joined units andinto the channel of said pair of units nearer the member.

4. The wall assembly of claim 3 wherein one of said units has its cornernearest the junction of the member and said means extending therefromrounded to facilitate the movement of the unit into normal positionwithin said assembly. I

References Cited in the file of this patent UNITED STATES PATENTS825,304 Dn Montier July 10, 1906 1,810,287 Mahon et al. June 16, 19312,069,176 Budd I an. 26, 1937 2,416,240 Strandlund Feb. 18, 19472,644,552 MacDonald July 7, 1953 2,659,461 Bowman Nov. 17, 19532,691,433 Farrier (Jet. 12, 1954 FOREIGN PATENTS 423,259 Italy July 10,1947 600,772 Great Britain Apr. 19, 1948 715,770 Great Britain Sept. 22,1954

